US7375951B2 - Load control device having a split enclosure - Google Patents

Load control device having a split enclosure Download PDF

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Publication number
US7375951B2
US7375951B2 US11/483,374 US48337406A US7375951B2 US 7375951 B2 US7375951 B2 US 7375951B2 US 48337406 A US48337406 A US 48337406A US 7375951 B2 US7375951 B2 US 7375951B2
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Prior art keywords
control device
load control
enclosure
electrical
operable
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US11/483,374
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US20080007897A1 (en
Inventor
Michael Hash
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Lutron Technology Co LLC
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Lutron Electronics Co Inc
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Priority to US11/483,374 priority Critical patent/US7375951B2/en
Assigned to LUTRON ELECTRONICS CO., INC. reassignment LUTRON ELECTRONICS CO., INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HASH, MICHAEL
Priority to BRPI0713214-0A priority patent/BRPI0713214A2/pt
Priority to MX2009000195A priority patent/MX2009000195A/es
Priority to CA 2658061 priority patent/CA2658061C/fr
Priority to EP20070810018 priority patent/EP2042004B1/fr
Priority to CN200780031518XA priority patent/CN101507357B/zh
Priority to PCT/US2007/015076 priority patent/WO2008008198A1/fr
Publication of US20080007897A1 publication Critical patent/US20080007897A1/en
Priority to US12/047,372 priority patent/US7499261B2/en
Application granted granted Critical
Publication of US7375951B2 publication Critical patent/US7375951B2/en
Priority to US12/168,977 priority patent/US7825609B2/en
Assigned to LUTRON TECHNOLOGY COMPANY LLC reassignment LUTRON TECHNOLOGY COMPANY LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LUTRON ELECTRONICS CO., INC.
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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B47/00—Circuit arrangements for operating light sources in general, i.e. where the type of light source is not relevant
    • H05B47/10—Controlling the light source
    • H05B47/175—Controlling the light source by remote control
    • H05B47/18—Controlling the light source by remote control via data-bus transmission
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B39/00—Circuit arrangements or apparatus for operating incandescent light sources
    • H05B39/04—Controlling
    • H05B39/08—Controlling by shifting phase of trigger voltage applied to gas-filled controlling tubes also in controlled semiconductor devices
    • H05B39/083—Controlling by shifting phase of trigger voltage applied to gas-filled controlling tubes also in controlled semiconductor devices by the variation-rate of light intensity
    • H05B39/085—Controlling by shifting phase of trigger voltage applied to gas-filled controlling tubes also in controlled semiconductor devices by the variation-rate of light intensity by touch control
    • H05B39/086—Controlling by shifting phase of trigger voltage applied to gas-filled controlling tubes also in controlled semiconductor devices by the variation-rate of light intensity by touch control with possibility of remote control
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/14—Structural association of two or more printed circuits
    • H05K1/148—Arrangements of two or more hingeably connected rigid printed circuit boards, i.e. connected by flexible means

Definitions

  • the present invention relates to a load control device for controlling the amount of power delivered from an alternating-current (AC) source to an electrical load.
  • the present invention relates to a load control device for receiving a first control signal having a first magnitude and for generating a second control signal having a second magnitude substantially greater than the first magnitude.
  • a conventional wall-mounted load control device is mounted to a standard electrical wall box and is coupled between a source of alternating-current (AC) power (typically 50 or 60 Hz line voltage AC mains) and an electrical load.
  • AC alternating-current
  • Standard load control devices such as dimmers and motor speed controls, use one or more semiconductor switches, such as triacs or field effect transistors (FETs), coupled in series between the source and the lighting load to control the power delivered to the load, and thus, the intensity of the lighting load or the speed of the motor.
  • FETs field effect transistors
  • the dimmer renders the semiconductor switch conductive for a portion of each line half-cycle to provide power to the lighting load, and renders the semiconductor switch non-conductive for the other portion of the line half-cycle to disconnect power from the load.
  • a GRAFIK Eye® Control Unit manufactured by the assignee of the present invention, includes a plurality of dimming circuits for control of a plurality of lighting loads and is operable to be coupled to a remote control wallstation via a low-voltage digital communication link.
  • the GRAFIK Eye Control Unit is operable to control each of the plurality of lighting loads in response to the digital control signals received from the remote control wallstation.
  • the GRAFIK Eye Control Unit is described in greater detail in commonly-assigned U.S. Pat. No. 5,430,356, issued Jul. 4, 1995, entitled PROGRAMMABLE LIGHTING CONTROL SYSTEM WITH NORMALIZED DIMMING FOR DIFFERENT LIGHT SOURCES, the entire disclosure of which is hereby incorporated by reference.
  • the National Electrical Code provides guidelines for the safe installation of electrical equipment and wiring.
  • the National Electrical Code (2005 Edition) defines a “Class 2 ” circuit as “the portion of the wiring system between the load side of a Class 2 power source and the connected equipment”.
  • Class 2 AC circuits are generally limited to 42.4 volts peak and 100 VA.
  • Class 2 direct-current (DC) circuits are generally limited to 60 volts and 100 VA.
  • Class 2 circuits include, for example, thermostats, burglary and security systems, cables (twisted-pair or coaxial) that interconnect computers for Local Area Networks, and limited-energy voice, intercom, and sound systems.
  • Low-voltage digital communication links coupled to lighting control devices e.g., the GRAFIK Eye Control Units, are typically classified as Class 2 circuits.
  • a load control device for installation in an electrical wallbox having a barrier comprises an electrical circuit, a first connector, a second connector, and a split enclosure.
  • the electrical circuit is operable to receive a first voltage having a first magnitude and to receive a second voltage having a second magnitude substantially larger than the first magnitude.
  • the first connector is operable to receive the first voltage and the second connector is operable to receive the second voltage.
  • the split enclosure has first and second enclosure portions and a gap between said first and second enclosure portions. The gap is operable to receive the barrier of the electrical wallbox when the load control device is installed in the wallbox.
  • the first connector is provided in a first opening of the first enclosure portion and the second connector is provided in a second opening of the second enclosure portion.
  • the load control device further comprises a support plate operable to mount the load control device to the wallbox, and a printed circuit board having the electrical circuit, the first connector, and the second connector mounted thereon, wherein the split enclosure and the printed circuit board are connected to the support plate such that the printed circuit board is contained between the split enclosure and the support plate.
  • the printed circuit board is preferably mounted to the support plate such that the printed circuit board is located externally to the electrical wallbox when the load control device is installed in the wallbox.
  • the electrical circuit is operable to couple a first voltage having a first magnitude and to couple a second voltage having a second magnitude substantially larger than the first magnitude.
  • the first and second voltages are operable to transit the load control device through first and second openings in the enclosure, respectively.
  • the first and second openings are adapted to be electrically isolated from each other by the barrier.
  • FIG. 1 is a simplified block diagram of a lighting control system including a load control device having a split enclosure according to the present invention.
  • FIG. 2 is a simplified block diagram of the load control device of FIG. 1 ;
  • FIG. 3 is a perspective view of a two-gang wallbox having a barrier
  • FIG. 4A is a rear perspective view of the load control device of FIG. 1 showing first and second portions of the split enclosure according to a first embodiment of the present invention
  • FIG. 4B is a bottom perspective view showing the load control device of FIG. 4A with the second portion of the split enclosure removed;
  • FIG. 4C is a bottom view of load control device of FIG. 4A with both portions of the split enclosure removed;
  • FIG. 5A is a rear perspective view of a load control device showing first and second portions of a split enclosure according to a second and preferred embodiment of the present invention
  • FIG. 5B is a bottom perspective view of the load control device of FIG. 5A showing first and second portions of the split enclosure;
  • FIG. 5C is a bottom perspective view of the load control device of FIG. 5A with both portions of the split enclosure removed;
  • FIG. 5D is a bottom view of the load control device of FIG. 5A with both portions of the split enclosure removed.
  • FIG. 1 is a simplified block diagram of a lighting control system 10 including a load control device 12 according to the present invention.
  • the load control device 12 is coupled to both a low-voltage communication link 14 , i.e., a Class 2 communication link, and a 277-V AC power source 18 , i.e., electrical light and power wiring.
  • a remote control device 15 is also coupled to the communication link 14 and is operable to transmit digital control signals to the load control device 12 via the communication link.
  • the communication link 14 may comprise, for example, a two-wire digital addressable lighting interface (DALI) communication link, as is well known in the art.
  • the communication link 14 is powered by a power supply 16 .
  • the load control device 12 receives both wires of the communication link 14 at first and second data terminals D 1 , D 2 .
  • the load control device 12 also receives a hot connection and a neutral connection from the 277-V AC power source 18 at a hot terminal H and a neutral terminal N, respectively.
  • the load control device 12 is operable to provide a 277-V AC dimmed hot signal at a dimmed hot output terminal DH to a 277-V AC ballast 20 in response to the digital control signals received on the communication link 14 .
  • the load control device 12 further provides a 277-V AC switched hot signal at a switched hot output terminal SH.
  • the ballast 20 controls the intensity of a fluorescent lamp 22 in response to the 277-V AC dimmed hot signal. Accordingly, a user is operable to control an intensity adjustment actuator (not shown) of the remote control device 15 to adjust the intensity of the fluorescent lamp 22 .
  • FIG. 2 is a simplified block diagram of the load control device 12 according to the present invention.
  • the load control device 12 comprises a first circuit portion 24 A and a second circuit portion 24 B.
  • the first circuit portion 24 A includes a first connector 26 A, which is coupled to the communication link 14 at the data terminals D 1 , D 2 .
  • the second circuit portion 24 B includes a second connector 26 B for receipt of the hot and neutral connections of the 277-V AC power source 18 at the hot terminal H and the neutral terminal N.
  • the second connector 26 B also provides the 277-V AC dimmed hot signal at the dimmed hot output terminal DH and the 277-V AC switched hot signal at the switched hot output terminal SH.
  • a power supply 32 is coupled between hot and neutral of the 277-V AC power source 18 for generating a direct-current (DC) voltage V CC for powering a controller 34 .
  • DC direct-current
  • the controller 34 is operable to open and close a mechanical switch, e.g., a relay 36 , which is coupled between the hot terminal H and the switched hot output terminal SH. Further, the controller 34 is operable to control a phase control circuit 38 , which is coupled between the switched hot output terminal SH and the dimmed hot output terminal DH. The controller 34 preferably controls the conduction time of a semiconductor switch (not shown) of the phase control circuit 38 to generate the 277-V AC dimmed hot signal.
  • An optocoupler 40 couples the digital control signals from the communication link 14 to a communication circuit 41 , such that the first circuit portion 24 A is electrically isolated from the second circuit portion 24 B.
  • the communication circuit 41 is operable to provide the digital control signals to the controller 34 at an appropriate voltage level, i.e., referenced between the DC voltage V CC of the power supply 32 and circuit common.
  • the controller 34 is operable to turn the fluorescent lamp 22 on and off via the 277-V AC switched hot signal and to control the intensity of the fluorescent lamp via the 277-V AC dimmed hot signal in response to the digital control signals received via the communication link 14 .
  • the communication link 14 could comprise a four-wire communication link, for example, an RS-485 communication link.
  • the first connector 26 A will have four terminals for connection to the four-wire RS-485 communication link.
  • the four wires comprise a common conductor, a power supply voltage conductor, and two data conductors (for transmission of the digital control signals).
  • the optocoupler 40 and the communication circuit 41 may be implemented on a single integrated circuit (IC), for example, part number MAX1480B, manufactured by Maxim Integrated Products.
  • the load control device 12 is adapted to be installed in a split wallbox, for example, the two-gang wallbox 42 of FIG. 3 , which has a barrier 44 separating the wallbox 42 into two sections 42 A, 42 B.
  • the barrier provides electrical isolation between the wallbox sections 42 A, 42 B.
  • the barrier 44 of such a wallbox 42 is removable.
  • the load control device 12 of the present invention is operable to be installed in the two-gang wallbox 42 with the first connector 26 A on one side of the barrier 44 and the second connector 26 B on the other side of the barrier 44 .
  • the load control device 12 of the present invention could alternatively be designed to be mounted in a three-gang or larger wallbox.
  • FIGS. 4A-4C show the load control device 12 according to a first embodiment of the present invention.
  • FIG. 4A is a rear perspective view of the load control device 12 showing first and second portions 50 A, 50 B of a split enclosure 50 .
  • FIG. 4B is a bottom perspective view showing the load control device 12 with the second portion 50 B of the split enclosure 50 removed.
  • FIG. 4C is a bottom view of load control device 12 with both portions 50 A, 50 B of the split enclosure 50 removed.
  • First and second printed circuit boards (PCBs) 52 A, 52 B are housed in the first and second portions 50 A, 50 B of the enclosure, respectively.
  • the first connector 26 A is mounted on the first PCB 52 A
  • the second connector 26 B is mounted on the second PCB 52 B.
  • the first and second connectors 26 A, 26 B are provided in openings 54 A, 54 B of the first and second portions 50 A, 50 B of the split enclosure 50 , respectively.
  • the first and second circuit portions 24 A, 24 B are mounted on the first and second PCBs 52 A, 52 B, such that the first and second circuit portions are separated by enough distance to maintain the electrical isolation between the two circuit portions.
  • the first and second PCBs 52 A, 52 B are connected via a PCB communication link, e.g., a ribbon cable 55 .
  • a PCB communication link e.g., a ribbon cable 55 .
  • the PCB communication link could be implemented as an infrared (IR) communication link or a radio-frequency (RF) communication link.
  • IR infrared
  • RF radio-frequency
  • the first and second portions 50 A, 50 B of the split enclosure 50 and the first and second PCBs 52 A, 52 B are mounted to a support plate 56 .
  • the support plate 56 acts as a faceplate for the load control device 12 when the load control device is mounted in an electrical wallbox.
  • the support plate 56 also functions as a heat sink to dissipate heat generated in the semiconductor switch of the phase-control circuit 38 .
  • the support plate 56 comprises a plurality of fins 58 to assist with the cooling of the support plate.
  • the support plate 56 includes mounting holes 60 for receipt of a screw (not shown) to be connected to the screw holes 46 of the wallbox 42 .
  • the support plate 56 also includes a channel 62 , which allows the ribbon cable 55 to be connected between the first and second PCBs 52 A, 52 B as shown in FIG. 4C .
  • the first and second portions 50 A, 50 B of the split enclosure 50 have extensions 64 that seal the channel 60 of the support plate 56 and prevent external materials from entering the interior of the load control device 12 .
  • the first and second portions 50 A, 50 B of the split enclosure 50 are spaced apart by a gap 66 .
  • the load control device 12 is operable to be mounted in the two-gang wallbox 42 having the barrier 44 , such that the barrier is received in the gap 66 between the first and second portions. Accordingly, the first and second connectors 26 A, 26 B will be separated by the barrier 44 , and thus, the voltages of the communication link 14 and the 277-V AC power source 18 will be separated appropriately to satisfy the National Electrical Code.
  • FIGS. 5A-5D show a load control device 68 having a split enclosure 70 according to a second and preferred embodiment of the present invention.
  • FIG. 5A is a rear perspective view and
  • FIG. 5B is a bottom perspective view of the load control device 68 showing first and second portions 70 A, 70 B of the split enclosure 70 .
  • FIG. 5C is a bottom perspective view and
  • FIG. 5D is a bottom view of the load control device 68 with both portions 70 A, 70 B of the split enclosure 70 removed.
  • the load control device 68 has a single PCB 72 , on which is mounted both the first and second circuit portions 24 A, 24 B.
  • the first and second circuit portions 24 A, 24 B are separated, for example, by a distance of 0.060 inches, and are coupled together via the optocoupler 40 , such that the first and second circuit portions are electrically isolated.
  • First and second connectors 76 A, 76 B are mounted on the PCB 72 and comprise the same terminals as the first and second connectors 26 A, 26 B of the load control device 12 according to the first embodiment.
  • the first connector 76 A is located in an opening 74 A of the first portion 70 A of the split enclosure 70 and the second connector 76 B is located in an opening 74 B of the second portion 70 B.
  • the split enclosure 70 comprises a base portion 75 to which the first and second portions 70 A, 70 B are affixed.
  • the PCB 72 is attached to a support plate 78 via attachment posts 80 .
  • a grounding lug 82 is attached to the support plate 78 to allow the load control device 68 to be connected to earth ground.
  • the support plate 78 functions as a heat sink for a semiconductor switch 84 , i.e., the semiconductor switch of the phase-control circuit 38 , which is thermally coupled to the support plate (as shown in FIG. 5D ).
  • the support plate 78 comprises a plurality of fins 86 to allow for cooling of the support plate.
  • a faceplate 88 is removably attached to the fins 86 of the support plate 78 to provide an improved aesthetic appearance of the load control device 68 .
  • the PCB 72 is housed by the base portion 75 of the split enclosure 70 such that the PCB 72 is located outside the electrical wallbox (not shown) to which the load control device 68 is mounted (note the level of the wall as shown in FIG. 5D ).
  • the base portion 75 comprises sidewalls 90 , which prevent external materials from entering the interior of the load control device 68 .
  • the base portion 75 further comprises mounting holes 92 that align with corresponding mounting holes 94 in the support plate 78 .
  • the mounting holes 92 , 94 allow the load control device 68 to be mounted to the wallbox 42 .
  • the load control device 86 of the second embodiment includes a gap 96 between the first and second portions 70 A, 70 B of the split enclosure 70 . Accordingly, the load control device 86 can be mounted in the wallbox 42 having the barrier 44 , such that the installation meets the requirements set forth by the National Electrical Code.
  • the present invention has been described with reference to a load control device for controlling a 277-V AC ballast in response to a digital control signal received via a digital communication link, the present invention could be applied to any load control device that is operable to receive two voltages that need to be separated in an electrical wallbox, for example, to satisfy an electrical standard such as the National Electrical Code.
  • the load control device could be operable to control a ballast in response to a phase-control signal having a first magnitude.
  • the ballast may be rated to operate at an operating voltage having a second magnitude, such that conductors at the first and second magnitudes may not be located within the same enclosure.
  • the load control device can be installed in a single electrical wallbox to receive the first phase-control signal at the first magnitude and generate a second phase-control signal at the second magnitude, while satisfying the requirements of the National Electrical Code.
  • the electrical circuitry of such a load control device which is often called a “power booster”, is described in greater detail in commonly-assigned U.S. Pat. No. 4,797,599, issued Jun. 10, 1989, entitled POWER CONTROL CIRCUIT WITH PHASE CONTROLLED SIGNAL INPUT, the entire disclosure of which is hereby incorporated by reference.

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US11/483,374 2005-05-02 2006-07-07 Load control device having a split enclosure Active 2026-10-07 US7375951B2 (en)

Priority Applications (9)

Application Number Priority Date Filing Date Title
US11/483,374 US7375951B2 (en) 2006-07-07 2006-07-07 Load control device having a split enclosure
CN200780031518XA CN101507357B (zh) 2006-07-07 2007-06-28 具有分离式外壳的负载控制装置
PCT/US2007/015076 WO2008008198A1 (fr) 2006-07-07 2007-06-28 dispositif de commande de charge ayant une enceinte en deux parties
MX2009000195A MX2009000195A (es) 2006-07-07 2007-06-28 Dispositivo de control de carga con un recinto dividido.
CA 2658061 CA2658061C (fr) 2006-07-07 2007-06-28 Dispositif de commande de charge ayant une enceinte en deux parties
EP20070810018 EP2042004B1 (fr) 2006-07-07 2007-06-28 Dispositif de commande de charge ayant une enceinte en deux parties
BRPI0713214-0A BRPI0713214A2 (pt) 2006-07-07 2007-06-28 dispositivo de controle de carga para a instalação de uma caixa elétrica de parede; para controlar a quantidade de energia liberada de uma fonte de energia ac para uma lámpada fluorescente; e para controlar a quantidade de energia liberada a uma carga elétrica
US12/047,372 US7499261B2 (en) 2006-07-07 2008-03-13 Load control device having a split enclosure
US12/168,977 US7825609B2 (en) 2005-05-02 2008-07-08 Electronic ballast having a flyback cat-ear power supply

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/483,374 US7375951B2 (en) 2006-07-07 2006-07-07 Load control device having a split enclosure

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US11/120,230 Continuation US7432661B2 (en) 2005-05-02 2005-05-02 Electronic ballast having a flyback cat-ear power supply

Related Child Applications (2)

Application Number Title Priority Date Filing Date
US12/047,372 Continuation US7499261B2 (en) 2006-07-07 2008-03-13 Load control device having a split enclosure
US12/168,977 Continuation US7825609B2 (en) 2005-05-02 2008-07-08 Electronic ballast having a flyback cat-ear power supply

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US20080007897A1 US20080007897A1 (en) 2008-01-10
US7375951B2 true US7375951B2 (en) 2008-05-20

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US11/483,374 Active 2026-10-07 US7375951B2 (en) 2005-05-02 2006-07-07 Load control device having a split enclosure
US12/047,372 Active US7499261B2 (en) 2006-07-07 2008-03-13 Load control device having a split enclosure

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Application Number Title Priority Date Filing Date
US12/047,372 Active US7499261B2 (en) 2006-07-07 2008-03-13 Load control device having a split enclosure

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US (2) US7375951B2 (fr)
EP (1) EP2042004B1 (fr)
CN (1) CN101507357B (fr)
BR (1) BRPI0713214A2 (fr)
CA (1) CA2658061C (fr)
MX (1) MX2009000195A (fr)
WO (1) WO2008008198A1 (fr)

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US20080150446A1 (en) * 2006-07-07 2008-06-26 Lutron Electronics Co., Inc. Load Control Device Having a Split Enclosure
US9504141B2 (en) 2014-08-07 2016-11-22 Abl Ip Holding Llc Dielectric barriers with mechanical attachment

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US8854798B1 (en) * 2009-10-02 2014-10-07 Qmotion Incorporated Transmitter holder apparatus and method
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US8749981B2 (en) * 2012-01-24 2014-06-10 General Electric Company Mounting base for circuit boards
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US9967954B2 (en) * 2016-01-15 2018-05-08 The Watt Stopper, Inc. Hybrid dimming controller with multi-class outputs
US9788374B1 (en) * 2016-06-01 2017-10-10 Elemental LED, Inc. LED driver systems adapted for gang boxes
US10116127B1 (en) 2017-12-12 2018-10-30 Elemental LED, Inc. Junction boxes with wrap-around compartments
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EP2042004B1 (fr) 2013-05-01
US20080007897A1 (en) 2008-01-10
BRPI0713214A2 (pt) 2012-04-10
US7499261B2 (en) 2009-03-03
CN101507357A (zh) 2009-08-12
CA2658061A1 (fr) 2008-01-17
CA2658061C (fr) 2014-04-08
CN101507357B (zh) 2012-09-26
US20080150446A1 (en) 2008-06-26
WO2008008198A1 (fr) 2008-01-17
EP2042004A1 (fr) 2009-04-01
MX2009000195A (es) 2009-03-20

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